Events

October 22, 2024
1:00 pm - 3:30 pm

On October 22nd, OpExChange had the privilege of touring their impressive water heater plant in McBee, SC. The focus of this visit was to share the development of the AO Smith Operating System (AOSos). The company's pioneering work in advanced welding techniques and glass-to-steel fusion revolutionized the manufacturing of products like pressure vessels, large-diameter pipes, and glass-lined water heaters. This innovation led to their prominence as a leading water heater manufacturer, introducing the first glass-lined water heater in 1936.

September 6, 2024
12:15 pm - 4:30 pm

Michelin opened its doors to OpExChange members for a rare look at how digital innovation is reshaping tire manufacturing. During a visit to the US7 plant in Lexington, teams from US5 and US7 showcased major projects—from Automated Guided Forklifts and augmented-reality work instructions to autonomous inspections performed by Spot, the robot dog. Members also toured the facility, witnessing production of some of the world’s largest tires. Beyond technology, Michelin highlighted its people-focused culture through the “Spark Team,” a design-thinking initiative that enhances the employee experience.

August 28, 2024
10:30 am - 11:30 am

The workers’ compensation process is often slow, costly, and full of waste—and Sargent Metal is proving it doesn’t have to be. In an OpExChange session, CEO Tim Hayden shared how his team is applying lean thinking and automation to fix a broken system. By partnering with Zenjuries, Sargent Metal has streamlined communication, reduced claim lag time, and taken control of the 70% of the process manufacturers can directly influence. The result: faster claim closure, lower reserves, and meaningful savings—while getting injured employees back to work sooner.

August 20, 2024
8:00 am - 12:00 pm

Wabtec’s Greenville plant recently hosted a safety “workout” with OpExChange peers, drawing participants from fifteen South Carolina manufacturers. Site Director Jason Williams and EH&S Manager Todd Davis shared how the team has been steadily building a stronger safety culture over the past three years, embedding safety into daily Gemba walks, performance objectives, and digital reporting tools like Gensuite. After touring the facility, participants collaborated on the key elements of a deep safety culture—leadership commitment, robust safety infrastructure, engagement at all levels, and behavior-based safety.

July 16, 2024
1:00 pm - 3:45 pm

Dish Network’s Spartanburg facility showcases how a strong lean culture can drive transformation. The 317,000-square-foot plant has shifted from high-volume operations to producing custom 5G cabinet enclosures and now complex cable and wire-harness assemblies. With an experienced team and a “Do It SomeHow!” mindset, the site blends engineering expertise with practical lean tools, from visual operations to hands-on simulations for every new hire. Their first external harness project highlights how this culture of innovation and continuous improvement is opening new opportunities for the Spartanburg team.

June 27, 2024
11:00 am - 12:00 pm

This webinar explored the vast potential of E-learning in today's manufacturing landscape. We were fortunate to have Adrienne Temple, Vice President of Training Programs for the South Carolina Manufacturers' Extension Partnership (SCMEP), and Greg Surtman, Workforce Development Manager of Tooling U-SME, share their valuable insights. There were 131 participants from 68 companies from 25 counties in South Carolina.

June 4, 2024
1:00 pm - 3:45 pm

Mactac’s Moore, SC facility showcased an impressive blend of automation, continuous improvement, and team-driven problem solving during their first OpExChange plant visit. Over the past two years, the site has transformed operations through proactive maintenance, laser-guided vehicles, a fully automated Ferretto warehouse, and a strong focus on waste reduction. Their shift from reactive to preventive maintenance, supported by Power BI analytics, has boosted uptime and efficiency, while waste levels have dropped dramatically. Most notable was the culture: a leadership team empowering talent, engaging employees, and embracing lean principles.

May 21, 2024
12:30 pm - 2:45 pm

Honda South Carolina Manufacturing welcomed the OpExChange for its first plant visit, offering a behind-the-scenes look at the world’s leading Honda side-by-side production facility. The Timmonsville plant—now 840,000 square feet and over 1,000 associates strong—showcased its award-winning manufacturing of the Honda Talon and its shift to advanced AGV and AGC technology. Visitors toured the high-speed assembly line, saw smart carts in action, and learned how Honda’s blend of innovation, ergonomics, and continuous improvement keeps production running at impressive efficiency.

May 7, 2024
1:00 pm - 3:45 pm

Rolls-Royce’s Aiken facility showcases precision, innovation, and sustainability in engine manufacturing. Visitors to the OpExChange tour saw advanced machining, assembly, predictive analytics, and the new Remanufacturing & Overhaul Center, supporting a circular economy. The plant features a solar-powered microgrid, strong safety programs, and a nationally recognized high school apprenticeship, reflecting Rolls-Royce’s commitment to people, technology, and delivering “power that matters to everyone.”

April 30, 2024
1:00 pm - 4:00 pm

Sargent Metal Fabricators in Anderson, SC showcased how a family-owned company can blend cutting-edge automation with deeply rooted values. Nearing its 50-year milestone, Sargent has transformed from a small sheet-metal shop into a highly advanced, 160,000-square-foot operation powered by robotic bending cells, fiber-laser cutting, modern welding technology, and in-house powder coating. During the OpExChange visit, guests saw firsthand how innovation, continuous investment, and a commitment to people have positioned Sargent Metal as a leader in precision fabrication. Their message was clear: automation isn’t just their future—it’s in their DNA.